Monolithic stud form for concrete wall production

ABSTRACT

A stud form and system for forming a preformed concrete wall panel having a solid portion and a plurality of vertical concrete studs joined to the solid portion. The stud form includes a substantially U-shaped channel having a face portion that defines an elongated plane and leg portions extending along side of and away from the elongated plane to define a predetermined channel depth. The stud form further includes means for integrally connecting the stud form to the solid portion of the wall panel with the channel opened toward the solid portion.

This application claims priority from U.S. patent application Ser. No.08/989,333, filed Dec. 11, 1997, now U.S. Pat. No. 6,003,278.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the field of prefabricatedconcrete wall construction, and more specifically, to a prefabricatedconcrete stud wall panel and method of forming the same.

2. Description of the Prior Art

In response to problems with traditional block construction methods,prefabricated wall panels were developed for rapid construction ofbuildings. Prefabricated wall panels are shown in U.S. Pat. Nos.4,751,803, 4,934,121, 5,055,252 and 5,313,753. Two types ofprefabricated concrete walls which are commonly used are cavity wallshaving open pockets between spaced vertical studs and planar wallshaving insulation panels between the vertical studs to form asubstantially planar surface. While both of these types of prefabricatedwall panels are generally superior to traditional block construction interms of costs, performance and reliability, there are still problemsassociated with both.

Many cavity walls use preformed concrete studs from a prior pour wherethey are formed separately from the top and base beams. A subsequentpour is then necessary to integrate the vertical studs with the top andbase beams. As a result, walls formed in this manner require additionalpouring and curing time and are often weaker than walls formed from amonolithic pour. Monolithic concrete cavity walls are typically formedby pouring concrete into frames which have forming channels for thevertical studs and the top and base beams. However, it is oftendifficult to remove the finished wall panel from the forming channelswithout damaging the concrete studs or beams.

In addition to the above, it is often necessary to provide a wood studat the face of the concrete studs. This is often accomplished by layingwood strips in the forming channels prior to pouring. Typically, thewood strips have a series of nails projecting therefrom and the concretecures around the nails to secure the wood studs. The process ofproviding nails in each of the wood strips is time consuming and adds tothe manufacturing costs. Additionally, the wood strips are susceptibleto cracking and warping, particularly when they are exposed to the wetconcrete.

The planar walls are typically formed by placing wall studs, insulation,and reinforcing means in a forming assembly and filling the assemblywith concrete. The studs and insulation are generally provided withprojections which are surrounded by the concrete to integrate the studsand insulation into the wall. Planar walls which utilize wood studsoften experience the same problems as the cavity walls do. U.S. Pat.Nos. 5,313,753 and 5,381,635 suggest mounting other common studs, metalor plastic studs, to the front faces of the concrete studs. However,these studs are merely secured to the front of the concrete studs bynarrow flanges which may pull from the concrete. As the size of theflanges is increased, the chance that the concrete will fail to flowbetween and around the flanges also increases. Another problemassociated with these metal and plastic studs on the vertical concreteface is that there is no way of passing service lines, such as, plumbingand electrical wiring, through the vertical studs.

Accordingly, there exists a need for a monolithic concrete wall which iseasy to form, includes integral attachment stud surfaces and overcomesthe disadvantages of the prior art.

SUMMARY OF THE INVENTION

The present invention generally relates to a stud form of a type used informing a preformed concrete wall panel having a solid portion and aplurality of vertical concrete studs joined to the solid portion. Thestud form includes a substantially U-shaped channel having a faceportion that defines an elongated plane and leg portions extending alongside of and away from the elongated plane to define a predeterminedchannel depth. The stud form further includes means for integrallyconnecting the stud form to the solid portion of the wall panel with thechannel opened toward the solid portion.

The present invention also includes preformed concrete walls whichincorporate the stud form and a system for forming such.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 an isometric view of a cavity wall panel made in accordance withthe present invention.

FIG. 1A is a partial sectional view of an alternate cavity wall panel.

FIG. 2 is an isometric view of a planar wall panel made in accordancewith the present invention.

FIG. 3 is an elevation view of a vertical stud form used in the wallpanel shown in FIG. 1.

FIG. 4 is a section view taken along the line 4—4 in FIG. 3.

FIG. 5 is a section of a cavity wall showing an alternate vertical studform.

FIG. 6 is a partial isometric view of the vertical stud form of FIG. 5.

FIG. 7 is a section of a cavity wall showing an alternate vertical studform.

FIG. 8 is a section of a cavity wall showing an alternate vertical studform.

FIG. 9 is a partial isometric view of an alternate vertical stud form.

FIG. 10 is an elevation view of a vertical stud form used in the wallpanel shown in FIG. 2.

FIG. 11 is a section view taken along the line 11—11 in FIG. 10.

FIG. 12 is an isometric view showing an assembly for the formation ofthe wall panel shown in FIG. 1.

FIG. 13 is an isometric view of a portion of an assembly for formationof the wall panel shown in FIG. 1 utilizing an alternate stud form.

FIG. 14 is an isometric view of a portion of the top and bottom formingmembers.

FIG. 15 is an alternate embodiment of the top and bottom formingchannels.

FIG. 16 is an isometric view of a horizontal stud form positioned in theforming assembly.

FIG. 17 is an isometric view showing an alternate assembly for theformation of the wall panel shown in FIG. 1.

FIG. 18 is an isometric view showing an assembly for the formation ofthe wall panel shown in FIG. 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments will be described with reference to thedrawing figures wherein like numerals represent like elementsthroughout. References to orientation refer to the orientation of aninstalled wall panel and are for clarity only.

FIG. 1 shows a cavity wall panel 1 made in accordance with the presentinvention. The cavity wall panel 1 preferably comprises spaced verticalstuds 10 extending between top beam 32 and base beam 34. The verticalstuds 10 include a filled stud channel 12 formed integral with the wallpanel 1. Insulation panels 30 are recessed from the inside face of thewall 1 and extend between the vertical studs 10 and top and base beams32 and 34. A concrete surface 36 extends along the back of the wallpanel 1.

As shown in FIG. 1A, the wall panel 1 may also include a connectionplate 27 extending along the top beam 32. The connection plate 27 ispreferably a wood stud with a plurality of lag bolts 29 extendingtherefrom. The connection plate 27 is positioned in the frame prior topouring and then the poured concrete cures around the lag bolts 29 tosecure the connection plate 27. The connection plate 27 permitsadditional framing members to be nailed directly to the wall panel 1.

FIG. 2 shows a preferred planar wall panel 101 made in accordance withthe present invention. The planar wall panel 101 generally comprisesspaced vertical studs 110 extending between top beam 132 and base beam134. The vertical studs include a filled stud channel 112 which isintegral with the wall panel 101. Insulation panels 130 extend betweenthe vertical studs 110 and with studs 110 form a planar inside face onthe wall 101. The outside face of the wall has a planer concrete surface136. A wire lath 138 may also be included behind the insulation panelsacross the entire area of the wall panel 101. A connection plate 27 mayalso be provided in the planar wall panel 101.

A first embodiment of a stud form 12 used in the cavity wall panel 1 isshown in FIGS. 3 and 4. It is preferably made from metal or plastic andforms an integral part of the vertical studs 10. The stud form 12 isgenerally a U-shaped channel. It is preferably slightly longer than thelength of a vertical stud 10 so that it extends into the top and basebeams 32 and 34 of the finished wall. Rebar 20 is positioned in each ofthe stud forms 12 to tie the vertical studs with the top and base beams32 and 34. Flanges 22 extend outward from each open end of the channeland are substantially parallel to the face of the form 12. Each of theflanges 22 has a plurality of projections 24 extending therefrom formaintaining the insulation panels 30 in position during forming of thecavity wall panel 1, as will be described in more detail hereinafter.Insulation 14 is placed in the stud form 12 U-channel and extends thelength thereof. The insulation 14 provides an area in each vertical stud10 which is substantially concrete free and allows screws or otherfasteners to be set directly into the stud forms 12 in the finishedwall. Since finishing materials, such as sheet rock, can be fasteneddirectly to the integral stud forms 12, separate nailing strips are notrequired.

As shown in FIGS. 3 and 4, sleeves 16 extend between the sides of thestud form 12 at various positions along its length. Each end of eachsleeve 16 is preferably flattened over to hold the side walls of thestud form 12 between the ends of the sleeve 16. In the finished wallpanel 1, the sleeves 16 are enclosed in the cured concrete and therebyintegrate the forms 12 with the finished wall. The sleeves 16 alsoprovide a conduit for electrical wires, plumbing and the like.

A plurality of weep holes 18 are provided through each side of the studform 12 near the front thereof. The weep holes 18 are checked duringpouring of the cavity wall panel 1 to ensure that concrete is properlyflowing to the front of the stud form 12.

Alternate embodiments of the cavity wall stud form 212 are shown inFIGS. 5-9. Each of these alternate cavity wall stud forms 212 has astructure similar to that of stud form 12 of FIGS. 3 and 4, however, thesupport flange 222 extends inward and has a interconnection flange 230extending therefrom. The support flanges 222 may be provided withprojections for maintaining the insulation panels 30 in position, butare generally not required.

In the embodiments of FIGS. 5, 6 and 9, each interconnection flange 230is a generally L-shaped member with a first portion 232 extendinggenerally parallel to the legs of the U-shaped channel and a secondportion 234 extending generally perpendicular thereto. The secondportion 234 extends into and embeds in the concrete vertical stud 10 tomaintain the stud form 212 in position. In the embodiment shown in FIG.7, the interconnection member 230 extends from the support flange 222 ata substantially 45° angle and embeds into the concrete stud 10 tomaintain the stud form 212 in position. In the embodiment shown in FIG.8, the interconnection member 230 extends generally perpendicular to thesupport flange 222. A plurality of holes 238 are provided in theinterconnection flange 230 along its length. The poured concrete flowsthrough the holes 238 and thereby interconnects the stud form 212 withthe concrete stud 10. As shown in FIG. 6, the interconnection flanges230 of each of these embodiments may be provided with holes 238 tofurther assist securing of the stud form 212.

As shown in FIGS. 5-8, insulation 214 generally occupies the U-shapedchannel of stud from 212. Since electrical wires, plumbing and the likecan be passed through openings 226 along the legs of the U-shaped forms212 and directly through the insulation 214, sleeves will generally notbe required. In an alternate embodiment shown in FIG. 9, the insulation214 may occupy only a portion of the U-shaped channel, thereby allowingconcrete to flow into and provide support therein. In such anembodiment, sleeves 216 are preferably provided to allow the electricalwires, plumbing and the like to pass through the vertical stud 10.

The vertical stud form 112 used to form the planar wall panels 101 isshown in FIGS. 10 and 11. The stud form 112 is generally the same as thecavity wall stud form 12 shown in FIGS. 3 and 4 except that the planarwall panel stud form 112 does not have flanges for supporting theinsulation since the insulation 130 will be adjacent to the stud form112. The stud form 112 may be provided with projections 124 to hold theinsulation panels 130.

Formation of a cavity wall panels 1 will now be described with referenceto FIGS. 12-17. Formation is generally the same for each of the cavitywall stud forms 12,212. FIG. 14 shows the intersection of two walls ofthe forming assembly 50. The forming assembly 50 preferably compriseslinear side walls 52 and top and bottom forming channels 54. Theinterior sides of the top and bottom forming channels 54 have a numberof spaced notches 56 for receiving the vertical stud forms 12,212. Thenotches 56 are preferably centered at sixteen or twenty-four inchesdepending on the desired configuration of the wall panel 1. As can beseen in FIG. 14, the end notches 56 preferably butt against the sidewalls 52 to allow the end vertical stud forms 12,212 having a flangealong only one edge or an inwardly extending flange, to be placedagainst the framing side walls 52.

In an alternate embodiment, shown in FIG. 15, the top and bottom formingchannels 54 have an interchangeable inner wall 54 b which fits into apermanent section of the channel 54 a. This allows varying inner channelsections 54 b, having differently spaced notches, at sixteen ortwenty-four inch centers for example, to be quickly interchanged toproduce a cavity wall panel 1 having the desired configuration.

With the forming assembly 50 in its desired configuration, the verticalstud forms 12 are laid in the notches 56. The stud forms 12 preferablyextend slightly into the top and bottom channels 54 to lock them intothe top and base beams 32 and 34 of the finished wall panel 1.Alternatively, the end of each stud form 12,212, or a portion thereof,extends the width of the respective channel 54 to abut the exterior wallof the channel 54 as shown in FIGS. 13 and 17. This helps to ensure thatthe stud form 12,212 maintains its position during pouring.

The rebar 20 in each stud form 12 also extends into the top and basechannels 54. The vertical rebar 20 is attached to horizontal rebar 60extending in the top and bottom channels 54. Various spacers and thelike are preferably used to maintain the rebar in position prior topouring. With the vertical stud forms 12 in place, the insulation panels30 are placed on the flanges 22 of adjacent stud forms 12 and extendbetween the top and bottom channels 54 and from one stud form flange 22to the adjacent stud form flange 22. In this position, the insulationdoes not cover the top and bottom channels 54 or the vertical stud form12 U-channels. The flange projections 24 maintain the insulation panels30 in position during pouring of the concrete. A monolithic concretepour is used to fill the forming assembly 50. The concrete fills the topand bottom channels 54 to form the top and base beams 32 and 34 and thevertical stud forms 12 to form the vertical studs 10. The concrete alsoprovides a solid back wall 36 of approximately two inches.

After the concrete cures, the wall panel 1 is lifted from the formingassembly 50. Since the vertical stud forms 12 are integral with the wallpanel 1, the likelihood that the vertical studs 10 will crack or beimproperly formed is greatly reduced. Furthermore, since the sleeves 16are integral with the wall panel 1, there is no need for drilling orcutting conduit passages in the vertical studs 10.

In an alternate embodiment of the cavity wall 1, all of the formingmembers 50 are linear walls. The top and bottom channels 54 are formedby horizontal stud forms 70 placed within the forming assembly 50, asshown in FIG. 16. The horizontal stud forms 70 are similar to thevertical stud forms 12 and also form an integral part of the wall panel1. The horizontal stud forms 70 differ from the vertical stud forms 12in that each has a side wall with notches 56 to receive the verticalstud forms 12. Formation of the wall panel 1 is simplified since thewall panel 1 does not require lifting from the top and bottom channels.Instead, the forming members 50 can simply be disassembled.

Another embodiment of the cavity wall panel 1 is shown in FIG. 17. Aswith the previous embodiment, the forming members 50 are linear walls.The stud forms 12,212 within the forming members 50 in their desiredlocations. Horizontal insulation panels 35 are positioned between theadjacent stud forms 12,212 and prevent the poured concrete from passingfrom the top and bottom beams 32 and 34 between adjacent stud forms12,212. Use of various size horizontal insulation panels 35 permitsgreater flexibility in positioning of the stud forms 12,212. Once thestud forms 12,212 are positioned, the remaining components are placed inthe frame, a monolithic concrete pour is provided and the completed wallpanel 1 is removed from the forming members in manner similar to thatdescribed above. The horizontal insulation panels 35 may be maintainedin the finished wall panel 1 or removed after removal of the wall panelfrom the forming members 50.

FIG. 18 shows the formation of a planar wall panel 101. Forming members152 are connected to define forming assembly 150. In the preferredembodiment, a stud form 112 is laid flat in the frame so that it extendsalong one of the end frame members 150. Additional stud forms 112 areplaced parallel to the first stud form 112 on sixteen or twenty fourinch centers. The studs forms 112 have a length which is less than thelength of forming members 152 whereby channels 154 exist at the top andbottom of the forming assembly 150.

Four inch thick expanded foam insulation panels 130, extending thelength of the stud forms 112, are placed between adjacent stud forms112. Reinforcing steel bars 160, extending the length of the wall panel101, are placed in the top and bottom channels 154. A wire mesh 138 islaid over the entire surface within the framing members. Conventionalwet concrete is poured into the form 150, filling all of the empty spacewithin the form and providing a slab of at least two inch (2″) thickconcrete along the entire back of the wall. The concrete will fill thetop and bottom channels and form the top and bottom beams 132 and 134.The concrete surrounds the sleeves 116 and thereby forms the integralvertical studs 110.

I claim:
 1. A stud form of a type used in forming a preformed concretewall panel characterized by: a substantially U-shaped channel having aface portion that defines an elongated plane and leg portions extendingalong side of and away from the elongated plane, each leg portionportion including a support portion adapted to support a portion of aninsulation panel; and means for integrally connecting the stud form tothe wall panel.
 2. The stud form of claim 1 wherein the connecting meansincludes at least one sleeve extending between the leg portions.
 3. Thestud form of claim 1 wherein each support portion has a plurality ofprojections for maintaining the insulation panel in position.
 4. Thestud form of claim 1 wherein each support portion extends generallyparallel to the elongated plane.
 5. The stud form of claim 1 whereineach leg portion has a given length and the face portion includesextension portions such that the face portion has a length greater thanthe length of each leg portion.
 6. The stud form of claim 1 wherein theconnecting means includes an additional leg portion extending from eachsupport portion.
 7. The stud form of claim 6 wherein each connecting legportion includes at least one aperture therethrough.
 8. The stud form ofclaim 6 wherein each connecting leg portion is a planar member.
 9. Thestud form of claim 8 wherein each connecting leg portion extends fromthe respective support portion at an angle relative to the elongatedplane.
 10. The stud form of claim 9 wherein the angle is approximately90 degrees.
 11. The stud form of claim 9 wherein the angle isapproximately 45 degrees.
 12. The stud form of claim 6 wherein eachconnecting leg portion is an L-shaped member.
 13. The stud form of claim12 wherein each connecting leg portion extends from the respectivesupport portion such that a portion of the L-shaped member extendsgenerally perpendicular to the elongated plane and a portion of theL-shaped member extends generally parallel to the elongated plane.
 14. Apreformed concrete wall panel comprising: a solid portion; a pluralityof vertical concrete studs; a plurality of insulating panels; aplurality of stud forms, each associated with a vertical concrete studand having: a substantially U-shaped channel having a face portion thatdefines an elongated plane and leg portions that extend along side ofand away from the elongated plane, each leg portion including a supportportion for supporting a portion of an insulation panel extendingbetween adjacent stud forms; and means for integrally connecting thestud form to the solid portion of the wall panel.
 15. The preformed wallof claim 14 wherein the wall is a cavity wall.
 16. The preformed wall ofclaim 14 further comprising top and bottom concrete beams.
 17. Thepreformed wall of claim 16 further comprising a stud form associatedwith each beam and having at least two legs, one of the legs having aplurality of notches for receiving the stud forms associated with thevertical studs.
 18. The preformed wall of claim 16 wherein the faceportion of each stud form includes extension portions which extend intothe respective beams.
 19. The stud form of claim 14 wherein theconnecting means includes at least one sleeve extending between the legportions.
 20. The stud form of claim 14 wherein each support portion hasa plurality of projections for maintaining the insulation panel inposition.
 21. The stud form of claim 14 wherein each support portionextends generally parallel to the elongated plane.
 22. The stud form ofclaim 14 wherein the connecting means includes an additional leg portionextending from each support portion.
 23. The stud form of claim 22wherein each connecting leg portion includes at least one aperturetherethrough.
 24. The stud form of claim 22 wherein each connecting legportion is an L-shaped member.
 25. The stud form of claim 24 whereineach connecting leg portion extends from the respective support portionsuch that a portion of the L-shaped member extends generallyperpendicular to the elongated plane and a portion of the L-shapedmember extends generally parallel to the elongated plane.
 26. The studform of claim 22 wherein each connecting leg portion is a planar member.27. The stud form of claim 26 wherein each connecting leg portionextends from the respective support portion at an angle relative to theelongated plane.
 28. The stud form of claim 27 wherein the angle isapproximately 90 degrees.
 29. The stud form of claim 27 wherein theangle is approximately 45 degrees.
 30. A system for forming preformedinsulated concrete walls in a single pour, the system comprising: aframe assembly that defines the overall perimeter of a wall; means forforming top and bottom beams within the frame assembly; a plurality ofinsulation panels; a plurality of stud forms extending between the topand bottom beam forming means, each stud form including: a substantiallyU-shaped channel having a face portion that defines an elongated planeand leg portions extending along side of and away from the elongatedplane, each leg portion including a support portion for supporting aportion of an insulation panel extending between adjacent stud forms;and means for integrally connecting the stud form to the wall panel.